How To Make Your Underpad Manufacturing Machine Run Stably For 10 Years: A Professional Maintenance Guide From Chinese Suppliers

Dear Valued Customers,

When you invest in a high-quality underpad manufacturing machine from China, you gain not only a production efficiency of 400-700 pieces per minute and a yield rate of over 97.8%, but also a long-term profit guarantee. However, improper or neglected maintenance during production will significantly reduce the equipment's production efficiency and service life. Based on our experience serving thousands of customers in 52 countries and regions worldwide, correct maintenance can extend the average service life of equipment from 5-6 years to 10-12 years, reduce annual downtime by more than 80%, and increase return on investment by 40%.

As your trusted long-term partner, we will share a globally verified full-lifecycle equipment management solution to help your production line achieve 24-hour uninterrupted stable operation.

I. Daily Preventive Maintenance: 15 Minutes a Day to Avoid Million-Dollar Losses

Preventive maintenance is the cornerstone of stable equipment operation. Most major failures stem from the accumulation of minor daily problems. We strongly recommend establishing a standardized "pre-shift - mid-shift - post-shift" inspection system:

Pre-shift Inspection (10 minutes before startup)

Safety system check: Confirm that emergency stop buttons, safety doors, and photoelectric protection devices are functioning properly

Air supply system check: Adjust air pressure to 0.6-0.8MPa and check for air leaks in the air pipes

Lubrication system check: Check the oil level at each lubrication point and replenish with the specified type of lubricant in a timely manner

Material tension check: Confirm that the tension settings for non-woven fabrics, PE films, SAP (Super Absorbent Polymer) and other raw materials are correct

Electrical system check: Observe the control cabinet indicator lights for abnormal alarms

Mid-shift Patrol Inspection (Every 2 hours, 2 minutes each time)

Listen to the equipment operation sound for abnormal friction or impact noises

Touch the surface temperature of servo motors and reducers, which should normally be below 60℃

Check for looseness or abnormal vibration in each transmission part

Observe the hot melt adhesive temperature and dispensing status to ensure uniformity and stability

Timely clean up scraps and dust generated during production

Post-shift Cleaning (5 minutes after shutdown)

Thoroughly clean dust, debris and residual hot melt adhesive on the surface and inside of the equipment

Turn off the air source, power supply and hot melt adhesive machine heating switch

Fill in the equipment operation record and document any abnormal phenomena

Organize tools and spare parts to keep the production area clean and tidy

Important Reminder: Never skip daily inspections. According to our statistics, 70% of equipment downtime accidents can be detected and avoided in advance through daily checks. A loose screw, if not tightened in time, may cause damage to a roller worth tens of thousands of yuan, resulting in several days of production interruption.

II. Regular Deep Maintenance: Execute According to Cycles to Fully Restore Equipment Performance and Extend Service Life

Daily preventive maintenance solves immediate problems during equipment operation, while regular deep maintenance is a systematic physical examination and functional repair of the equipment. It can eliminate accumulated problems that daily maintenance cannot reach, correct gradually offset precision, and delay the aging process of core components. According to statistical data from thousands of production lines we serve in 52 countries worldwide: Equipment that strictly implements standardized regular maintenance has a 42% longer average service life of core components, a 60% higher equipment precision retention rate, and a 75% reduction in annual yield loss due to performance degradation.

Based on the operating characteristics and wear patterns of underpad manufacturing machines, we divide regular deep maintenance into four levels: weekly maintenance, monthly maintenance, seasonal maintenance, and annual maintenance. Each level corresponds to different maintenance depths and key contents, which must be strictly implemented according to the cycle.

Weekly Maintenance (1 hour of downtime per week, basic deep maintenance)

The core goal of weekly maintenance is to remove dust and wear debris generated during one week of operation, check the status of easily loosened and fatigued components, and prevent small problems from accumulating into major failures. All operations must be performed after the equipment is completely shut down and the power and air sources are cut off:

Special Cleaning of Photoelectric and Proximity Sensors

Gently wipe all sensor surfaces with a lint-free cloth dipped in anhydrous alcohol. Never use hard objects, steel wool or corrosive solvents to avoid scratching the lens and sensing surface

Key cleaning points: Material deviation correction sensors, SAP spreading amount detection sensors, product counting sensors, safety door proximity switches, mold positioning sensors

Power on and test after cleaning to confirm that the sensor sensing distance and sensitivity are normal, with no false triggers or missed detections

Transmission System Tension and Wear Inspection

Check the tightness of all transmission chains and timing belts. The standard is: When pressing the middle of the chain/belt vertically with your finger, the sag should be controlled at 10-15mm

Observe whether the chain links are rusted or deformed, and whether the timing belt tooth surface has cracks, missing teeth or abnormal wear. Replace immediately if there is obvious damage

Apply special chain grease to the chain to ensure that each link is fully lubricated and avoid dry friction

Lubrication of Sliding and Rotating Parts

Inject special guide rail oil into all linear sliding guide rails and guide posts. The injection amount should be such that a uniform oil film is formed on the guide rail surface to avoid excessive oil causing product contamination

Inject lithium-based grease into all exposed bearings and bushings, with the injection amount being 1/3-1/2 of the bearing cavity volume

Check the working status of the automatic lubrication system to confirm that the oil pump supplies oil regularly and the oil circuit is not blocked

Hot Melt Adhesive System Deep Cleaning

Turn off the heating switch of the hot melt adhesive machine. When the adhesive temperature drops to 80-100℃, take out the filter screen and clean the carbonized adhesive blocks and impurities on the screen with a special cleaning agent

Check the glue gun nozzle for clogging or stringing, and clean the nozzle hole with a needle

Clean the overflowing adhesive on the surface of the glue tank and glue delivery pipe to prevent the adhesive from solidifying and affecting heat dissipation

Comprehensive Fastener Tightening

Use a torque wrench to tighten all exposed bolts and nuts according to the specified torque. Key inspection points: Roller bearing seat bolts, mold fixing bolts, motor mounting bolts, frame connection bolts

Check for looseness or falling off of pins and circlips at each part, and replenish missing fasteners in a timely manner

Mark parts that are prone to loosening for key inspection during the next maintenance

Monthly Maintenance (4 hours of downtime per month, system performance inspection)

The core goal of monthly maintenance is to check the operating parameters and performance status of each system of the equipment, calibrate key detection devices, and eliminate potential systematic failures:

Servo Drive System Performance Testing

View the operation history data of all servo motors and drives through the equipment control system, focusing on: operating current, peak torque, motor temperature, alarm records

Measure the temperature of the servo motor housing and drive heat sink with a thermometer, which should normally be below 65℃. If it exceeds 70℃, check the cooling fan and load conditions

Check for looseness or damage of encoder connection cables to ensure stable signal transmission

Perform a servo motor origin reset test to confirm that the positioning accuracy meets the requirements

Machine Vision Inspection System Calibration

Calibrate the precision of the vision inspection system with a standard calibration template, and adjust the light source brightness, contrast and exposure time

Test the system's recognition rate for common defects, including missing pieces, missing glue, uneven SAP spreading, size deviation, stains, etc., requiring a recognition rate of over 99.5%

Clean the light source and reflector of the vision system to ensure uniform light

Back up the parameters and programs of the vision inspection system to prevent data loss

Power Auxiliary System Maintenance

Check the oil level and oil quality of the vacuum pump. Replenish with the specified type of vacuum pump oil when the oil level is below the minimum scale line, and replace immediately when the oil quality turns black or emulsified

Replace the vacuum pump air filter and exhaust filter, clean the gas-water separator, and drain condensed water

Check the oil level and pressure of the air compressor, replace the air filter, and check whether the safety valve and pressure gauge are normal

Clean the condensed water in the compressed air pipeline and check whether the pressure of each branch pressure regulating valve is stable

Electrical Control System Dust Removal and Inspection

Open the electrical control cabinet door and blow the dust inside the cabinet with dry compressed air at a pressure of 0.2-0.3MPa. Never blow directly at electrical components

Check all wiring terminals for looseness, oxidation or ablation, and retighten loose terminals

Check the operating status of the cooling fan, clean the dust on the fan and heat sink to ensure good heat dissipation

Check the battery voltage and charge-discharge status of the UPS power supply, and test the power-off switching function

Comprehensive Pneumatic System Inspection

Check the running speed and stability of all cylinders for crawling or jamming, and apply special grease to the cylinder piston rods

Check all air pipe joints, solenoid valves and cylinders for air leaks with soapy water, and replace aging sealing rings and air pipes in a timely manner

Test whether all solenoid valves operate sensitively and reliably, and check the accuracy of pressure regulating valves and pressure gauges

Clean the water cup and oil cup of the pneumatic triple piece, and replenish pneumatic lubricating oil in a timely manner

Seasonal Maintenance (Performed once in March-April and September-October each year, 8 hours of downtime each time, environmental adaptability maintenance)

Seasonal maintenance is a special maintenance carried out in response to the impact of significant changes in temperature and humidity during seasonal transitions, which is particularly important for areas with large temperature differences. Changes in temperature and humidity will lead to changes in material properties, lubricant viscosity changes, and electrical components getting damp, thus causing a series of failures:

Seasonal Oil Replacement

Replace hydraulic oil and lubricant with appropriate viscosity according to the local seasonal temperature: ISO VG 46 anti-wear hydraulic oil and No. 00 lithium-based grease are recommended in summer; ISO VG 32 anti-wear hydraulic oil and No. 0 lithium-based grease are recommended in winter

Completely drain the old oil, clean the oil tank, oil filter and oil circuit, and ensure no residual old oil before adding new oil

Check the working status of the oil cooler and oil heater to ensure that the oil temperature is controlled within the normal range

Special Reducer Inspection and Maintenance

Check the oil level and oil quality of all reducers. The oil level should be in the middle of the oil gauge scale line. Replace immediately when the oil quality is turbid or contains impurities

Observe whether the reducer has oil leakage, and replace aging oil seals and gaskets in a timely manner

Listen to the noise and vibration of the reducer during operation. If there is abnormal impact sound or severe vibration, disassemble and check the wear of gears and bearings

Comprehensive Tension Control System Calibration

Since temperature changes will alter the tensile properties of raw materials such as non-woven fabrics and PE films, it is necessary to recalibrate the tension parameters of all unwinding, rewinding and intermediate sections

Check the accuracy of the tension sensor and calibrate it with standard weights

Test the response speed and accuracy of the deviation correction system to ensure smooth material operation without deviation

Temperature Control System Calibration and Maintenance

Use a contact thermometer to perform multi-point measurements on the temperature of heating rollers, cooling rollers and hot melt adhesive machines, compare the difference between the displayed temperature and the actual temperature, and calibrate the temperature sensor when the error exceeds ±2℃

Clean the dirt, residual glue and scale on the surface of heating rollers and cooling rollers to ensure uniform heat transfer

Check for clogging or leakage of heating pipes and cooling water pipes, and unclog and repair in a timely manner

Comprehensive Safety System Testing and Upgrade

Test all safety devices one by one, including: emergency stop buttons, safety door interlocks, photoelectric protection, overload protection, leakage protection

Measure the grounding resistance of the equipment to ensure that the grounding resistance is less than 4Ω

Check the validity period and pressure of fire fighting equipment, and update aging safety warning signs

Check the operating status of workshop dehumidifiers and air conditioners, adjust temperature and humidity control parameters to ensure the workshop environment is maintained at 18-28℃ and humidity 40%-60%

Annual Maintenance (Recommended to be performed by our professional engineers on-site, 2-3 days of downtime each time, complete machine in-depth overhaul and performance recovery)

Annual maintenance is a comprehensive disassembly, inspection, repair and upgrade of the equipment, equivalent to a "major surgery" for the equipment, which can restore the equipment's factory performance to the greatest extent. Since it involves the disassembly and precise calibration of core components, we strongly recommend that it be performed by our professionally trained engineers. Non-professional operation may lead to permanent degradation of equipment precision:

Comprehensive Transmission System Disassembly and Inspection

Disassemble core transmission components such as gearboxes, sprocket sets, transmission shafts, and couplings

Check the tooth surface wear, pitting, and gluing of gears. Gears must be replaced when the tooth thickness wear exceeds 10% or severe pitting occurs

Check the coaxiality and bending degree of the transmission shaft. Correct or replace when the error exceeds 0.05mm/m

Check for aging or cracking of the elastic elements of the couplings and replace in a timely manner

Batch Replacement of Worn Parts

Replace all bearings with excessive wear. Judgment criteria: Radial clearance exceeds 0.1mm or axial clearance exceeds 0.2mm

Replace all seals and oil seals with leakage phenomena

Inspect and replace severely worn scrapers, blades, guide rollers and mold components

Replace aging wires, cables and air pipes

Control System Upgrade and Optimization

Upgrade the equipment PLC (Programmable Logic Controller) control system and HMI (Human-Machine Interface) software to the latest version, fix system vulnerabilities, and add new functions

Back up all control programs and production parameters and archive them

Optimize control algorithms to improve the stability and response speed of equipment operation

Inspect and upgrade the safety control system to ensure compliance with the latest international safety standards

Full System Sensor and Instrument Calibration

Calibrate all temperature, pressure, tension, speed and displacement sensors with standard measuring instruments

Calibrate all display instruments such as pressure gauges, thermometers and flow meters

Adjust the zero point and range of sensors to ensure that the measurement accuracy meets the requirements

Replace aging or precision-degraded sensors

Complete Machine Performance Test and Acceptance

After completing all maintenance items, conduct a continuous full-load production test for more than 8 hours

Test various performance indicators of the equipment, including: production speed, yield rate, energy consumption, noise, vibration

Adjust various production parameters to the optimal state to ensure product quality meets standards

Issue a detailed "Equipment Annual Health Report", including equipment status assessment, existing problems, next year's maintenance recommendations and spare parts replacement plan

Maintenance Record Management: Establish a Full-Lifecycle Equipment Health File

Perfect maintenance records are the core of equipment management, which can help you accurately track equipment status, predict failure occurrence time, optimize maintenance plans, and reduce maintenance costs. Please be sure to establish a detailed equipment maintenance file, which should include the following contents:

Basic equipment information: Equipment model, factory number, purchase date, installation and commissioning date

Detailed records of each maintenance: Maintenance date, maintenance level, maintenance personnel, completed maintenance items, inspection results

Parts replacement records: Name, model, quantity, replacement date, replacement reason of replaced parts

Fault handling records: Fault occurrence time, fault phenomenon, fault cause, processing method, processing result

Equipment performance test records: Regular test data of key indicators such as production speed, yield rate, energy consumption

Next maintenance plan: Time of next maintenance, expected maintenance items and required spare parts

It is recommended to use an electronic management system to manage maintenance records for easy query, statistics and analysis. Regularly review maintenance data to identify weak links and vulnerable parts of the equipment, stock spare parts in advance, adjust maintenance cycles, and achieve the transformation from "passive maintenance" to "active prevention". At the same time, complete maintenance records are also an important basis for equipment warranty, second-hand transfer and insurance claims, please keep them properly for at least 10 years.

III. Correct Operation Specifications: Train Qualified Personnel to Avoid Human Damage from the Source

Improper human operation is the second leading cause of unplanned equipment downtime, accounting for 25% of all failure statistics of global customers, and more than 90% of human failures can be completely avoided through standardized operation. According to our after-sales data, the average single repair cost of equipment damage caused by illegal operations exceeds $12,000, with downtime lasting 3-7 days, resulting in direct and indirect losses of up to hundreds of thousands of dollars for customers.

As your long-term partner, we have established a standardized equipment operation system. All operators must strictly abide by the following specifications, which is the basic premise to ensure the long-term stable operation of the equipment:

1. Receive Professional Training: No Operation Without Training

All operators must receive our professional systematic training and pass the assessment before they can work independently. This is an insurmountable red line to ensure the safe operation of the equipment.

Training content and duration: We provide 7-10 days of free systematic training during equipment installation and commissioning, covering five modules: equipment structure principle, daily operation process, maintenance methods, common fault troubleshooting, and safety operation procedures, combining theory with practical operation to ensure that each student can master it proficiently

Strict assessment mechanism: After the training, theoretical examination and practical operation assessment will be conducted. Only those who pass both examinations will be issued a training qualification certificate. Those who fail the assessment need to participate in retraining until they pass

Regular retraining requirements: We recommend retraining and skill assessment for operators every 6 months, and safety training once a year to update operational knowledge and safety awareness in a timely manner. For new operators, they must receive complete training again. Informal training in the form of "old employees teaching new ones" is strictly prohibited

Lifelong training support: We provide lifelong free operator retraining services for all customers. Whether it is new employee onboarding or equipment upgrade and transformation, you can contact us at any time to arrange training

2. No Over-Specification Production: Keep the Equipment Design Red Line

Each equipment has its design limits calculated and tested strictly. Forcing over-specification production is the most fatal damage to the equipment, which will lead to accelerated wear of core components, permanent degradation of equipment precision, and even major safety accidents.

No over-speed production: For example, equipment with a designed maximum speed of 500 pieces per minute is strictly prohibited from running at more than 550 pieces per minute for a long time. According to our tests, long-term operation at 20% over speed will shorten the overall service life of the equipment by 30%-40%, shorten the service life of transmission components such as bearings and gears by more than 50%, and reduce the yield rate by 3%-5%

No use of over-specification raw materials: The equipment has clear standards for the raw material gram weight range and width tolerance. For example, the surface non-woven fabric gram weight range is 20-30g/㎡. Using non-woven fabric below 18g/㎡ will cause frequent material breakage, and using non-woven fabric above 35g/㎡ will increase transmission load and damage the tension control system and rollers

No overloaded continuous operation: The designed continuous operation time of the equipment is 24 hours a day, but it is recommended to shut down for 4-8 hours of maintenance every 7 days of operation. Long-term uninterrupted operation will cause equipment fatigue damage and a sharp increase in failure rate

3. Strictly Implement Shutdown Operation System: No Maintenance or Cleaning During Operation

Performing any maintenance, cleaning or adjustment operations while the equipment is running is extremely dangerous, which may not only lead to serious personal injury accidents, but also cause major equipment damage.

Mandatory shutdown and power-off requirements: Any maintenance, cleaning, adjustment, and mold changing work must be performed after the equipment is completely shut down, the main power and air sources are cut off, and a "Under Maintenance, No Switching On" warning sign is hung

No "running with faults": When abnormal sound, vibration, odor or alarm is found in the equipment, press the emergency stop button immediately to shut down and check. Do not continue production until the fault is eliminated. Running with faults will quickly worsen small problems. For example, a loose bearing, if not replaced in time, may cause major accidents such as shaft breakage and roller damage

No illegal operations: It is strictly prohibited to remove or shield safety devices such as safety doors, photoelectric protection, and emergency stop buttons; it is strictly prohibited to extend hands, tools or other objects into the equipment during operation; it is strictly prohibited to cross the safety guardrails of the equipment

4. Standardized Production Change Process: Fast Production Change Without Sacrificing Equipment Precision

Our modular design reduces production change time from the traditional 2-3 hours to less than 25 minutes, but this does not mean that production change steps can be simplified. Irregular production change operations are one of the main causes of mold damage and product quality degradation.

Strictly follow the production change manual: We provide a detailed "Production Change Operation Manual" for each equipment, including production change steps, parameter settings and precautions for all product specifications. Operators must strictly follow the manual steps, and skipping steps or rough operation is strictly prohibited

Mold installation and calibration: When replacing the mold, special tools must be used, and the fixing bolts should be tightened evenly to ensure that the mold is installed firmly and positioned accurately. After installation, no-load trial operation must be carried out to check the mold gap and operation status, and production can only be started after confirmation

Parameter adjustment specifications: During production change, only parameters related to product specifications, such as length, width, tension, etc., can be adjusted. It is strictly prohibited to modify the basic operating parameters of the equipment. When adjusting parameters, make fine adjustments step by step, and conduct trial production after each adjustment to confirm that the product quality is qualified before formal production

5. Parameter Protection System: No Random Modification of Equipment Core Parameters

All parameters in the equipment control system are the optimal values determined by our engineers after thousands of tests and optimizations. Random modification of parameters will lead to unstable equipment operation, degraded product quality, and even equipment failure.

Hierarchical authority management: Our equipment control system adopts three-level authority management: Operators can only view and adjust production parameters, team leaders can adjust some process parameters, and only our engineers can modify the core operating parameters of the equipment

Core parameters that are prohibited from modification: Including servo motor gain, tension control parameters, heating temperature upper limit, safety protection threshold, PLC program, etc. These parameters are directly related to the operation safety and performance of the equipment and are not allowed to be modified by customers under any circumstances

Parameter adjustment application process: If it is really necessary to adjust equipment parameters to adapt to special raw materials or product requirements, please contact our technical engineers in advance, adjust under the remote guidance of the engineers, or have the engineers come to the site for adjustment. The adjusted parameters need to be verified and recorded

IV. Consumables and Spare Parts Management: Use High-Quality Materials and Stock Sufficient Parts to Achieve Zero-Wait Production

Consumables and spare parts are the "blood" and "food" of the equipment, and their quality and supply timeliness directly determine the operation stability and production continuity of the equipment. Many customers use inferior consumables or do not stock spare parts to save short-term costs, resulting in frequent equipment failures and extended downtime, ultimately causing greater losses.

1. Must Use Original or Certified High-Quality Consumables

Inferior consumables are invisible killers of equipment, and the losses they cause are often dozens or even hundreds of times the price of the consumables themselves. We strongly recommend that you only use original consumables provided by us or our certified high-quality consumables, which is the most economical choice to ensure the long-term stable operation of the equipment.

(1) Hot Melt Adhesive: The Core of the Equipment Bonding System

Recommended product: Henkel TECHNOMELT® DM 2866U medical-grade hot melt adhesive for hygiene products, with a softening point of 88–92℃ and a use temperature of 150–170℃. It has the characteristics of strong adhesion, good fluidity, low odor, no stringing, excellent thermal stability, and no sensitizing ingredients. It is specially designed for multi-layer composite bonding of disposable hygiene products such as underpads, diapers, and medical dressings, and meets FDA and ISO 10993 medical biocompatibility requirements. It is a globally recognized mainstream best-selling model in the hygiene products industry

Hazards of inferior hot melt adhesive:

Contains a large amount of impurities and fillers, which are easy to carbonize and clog glue gun nozzles and filters, resulting in broken glue and uneven glue lines, increasing an average of 8-12 hours of downtime for cleaning per month

Insufficient adhesion leads to product delamination and degumming, reducing the yield rate by 5%-10%

Produces harmful gases at high temperatures, endangering the health of operators

Carbonized particles will scratch glue rollers and scrapers, leading to their early scrapping. The cost of replacing a set of glue rollers and scrapers exceeds $5,000

Usage precautions: Strictly control the hot melt adhesive temperature between 150-170℃. Excessively high temperature will cause carbonization of the adhesive, and too low temperature will affect adhesion; turn off the heating switch 15 minutes in advance before each shutdown to allow the adhesive in the glue gun to flow out fully

(2) Lubricating Oils/Greases: The "Blood" of the Equipment Transmission System

Different parts of the equipment require different types of lubricating oils/greases. Mixing or using inferior products is strictly prohibited.

Guide rail oil: Linear guide rails use ISO VG 68 guide rail oil, which has good anti-wear and anti-oxidation properties, can form a uniform oil film on the guide rail surface, and reduce friction and wear

Gear oil: Reducers use ISO VG 220 industrial gear oil, which has excellent load-bearing capacity and extreme pressure resistance, and can effectively protect gears and bearings

Grease: Bearings and chains use No. 00 lithium-based grease, which has good mechanical stability and water resistance, and is suitable for lubrication of high-speed rotating parts

Hazards of inferior lubricating oil: Unstable viscosity, unable to form an effective oil film, leading to accelerated wear of bearings and gears, shortening their service life by more than 50%; contains impurities, which will scratch the surface of moving parts; easy to oxidize and deteriorate at high temperatures, producing oil sludge and blocking oil circuits

Replacement cycle: Guide rail oil is replenished once a month and replaced once a quarter; gear oil is replaced once every six months; grease is injected once a month

(3) Filter Elements: The "Respiratory System" of the Equipment

The function of filter elements is to filter impurities in the air, pollutants in the oil, and scale in the cooling water to ensure the normal operation of each system of the equipment.

Air filter: Used in air compressors, vacuum pumps, and electrical cabinet cooling systems, with a filtration accuracy of 5μm. Check once a month and replace every 3 months. A clogged air filter will lead to insufficient air intake, increased load on air compressors and vacuum pumps, and increased energy consumption by 20%-30%

Oil filter: Used in hydraulic systems and lubrication systems, with a filtration accuracy of 10μm. Replace every quarter. A clogged oil filter will lead to unstable oil pressure, poor lubrication, and accelerated wear of hydraulic components and transmission parts

Water filter: Used in cooling systems, with a filtration accuracy of 20μm. Replace every six months. A clogged water filter will lead to reduced cooling effect, excessive equipment temperature, affecting product quality and equipment life

2. Establish a Scientific and Reasonable Spare Parts Inventory System

The "zero inventory" concept is not applicable to spare parts management of production equipment. A reasonable spare parts inventory is the key to reducing downtime waiting time. According to our experience serving global customers, scientific spare parts inventory can shorten the average failure downtime by more than 70%.

We use the ABC classification method to classify and manage spare parts, and recommend that you establish a spare parts inventory according to the following standards:

(1) Class A Spare Parts: Wearing Parts (Regular Inventory, 3-6 Months Usage)

These spare parts are low in price, large in consumption, and high in replacement frequency. They are the most commonly used spare parts in daily maintenance and must be kept in sufficient stock.

Mainly include: Various blades, scrapers, timing belts, chains, bearings, sealing rings, glue nozzles, filter elements, proximity switches

Stocking recommendation: According to the equipment operation time and the average service life of spare parts, stock 3-6 months of usage. For example: Blades are replaced every 1-2 months, stock 6 pieces; bearings are replaced every 1-2 years, stock 2-4 pieces

(2) Class B Spare Parts: Critical Spare Parts (Emergency Inventory, 1-2 Sets)

These spare parts are high in price, long in service life, but once damaged will cause the equipment to shut down completely, and the procurement cycle is long. 1-2 sets must be stocked as emergency supplies.

Mainly include: Servo motors, servo drives, PLC modules, touch screens, tension sensors, vision inspection cameras, solenoid valves, vacuum pumps

Stocking recommendation: Stock 1 set of core electrical spare parts and 1 set of key pneumatic spare parts per equipment. For customers with multiple identical equipment, the stocking quantity can be appropriately reduced to realize spare parts sharing

(3) Class C Spare Parts: Special Spare Parts (Stock on Demand, Sign Consignment Agreement)

These spare parts are expensive, long in service life, low in damage probability, but very long in procurement cycle. It is not recommended for customers to stock them by themselves. We can provide spare parts consignment services for long-term cooperative customers.

Mainly include: Hot melt adhesive machine main units, rollers, molds, reducers, frame components

Consignment service content: We will store the spare parts in your factory. You do not need to pay in advance, and only settle after using the spare parts. The ownership of unused spare parts belongs to us, and we will conduct regular inspections and updates

3. Global Spare Parts Supply Guarantee System

We have established a global spare parts supply network to ensure that you can quickly obtain the required spare parts at any time and minimize downtime losses.

Regional spare parts warehouses: We have regional spare parts warehouses in major cities around the world, stocking all commonly used spare parts, which can be delivered to your factory within 24-48 hours

Emergency air freight service: For special spare parts not available in regional warehouses, we can air freight from our Chinese headquarters via international express, delivering to major global cities within 3-5 days

Spare parts traceability system: We have established a complete spare parts file for each equipment. You can query the model, price, inventory and delivery time of spare parts through our customer service system, and place orders online

Old parts recycling service: For replaceable repairable spare parts, we provide old parts recycling and repair services. The repair cost is only 30%-50% of new parts, helping you reduce spare parts costs

V. Production Environment Optimization: Create the Best Operating Conditions for Equipment

Many customers often ignore the impact of the production environment on equipment. In fact, a harsh production environment is an important hidden factor leading to premature aging and frequent failures of equipment. According to our research, equipment operating in a standard-compliant environment has an average service life of more than 40% longer and a failure rate of more than 60% lower than equipment operating in a harsh environment.

Please ensure that your production workshop meets the following environmental requirements to create a "comfortable" operating environment for your equipment:

1. Temperature Control: 18-28℃ Constant Temperature Environment

Temperature has a significant impact on the electrical system, transmission system and raw material performance of the equipment. Excessively high or low temperatures will lead to unstable equipment operation.

Hazards of excessively high temperature:

Accelerated aging of electrical components. For every 10℃ increase in temperature, the service life of electrical components is shortened by 50%

Overheating of servo motors and drives, leading to overload alarm shutdown

Difficult to control hot melt adhesive temperature, easy to carbonize and clog

Operators are prone to fatigue, increasing the probability of operational errors

Hazards of excessively low temperature:

Increased lubricant viscosity and poor fluidity, leading to increased transmission resistance and 15%-20% higher energy consumption

Slow response of hydraulic system and sluggish action

Poor fluidity of hot melt adhesive and reduced adhesion

Shrinkage of metal parts, leading to changes in fit clearance and reduced equipment precision

Solution: Install industrial air conditioners and heaters to keep the workshop temperature stable at 18-28℃ throughout the year. For the electrical control cabinets and servo drives of the equipment, it is recommended to install separate air conditioners for cooling.

2. Humidity Control: 40%-60% Relative Humidity

Humidity has a huge impact on the electrical system, metal parts and raw material performance of the equipment, and is the root cause of many hidden failures.

Hazards of excessively high humidity:

Condensation in electrical cabinets, leading to short circuit and burning of electrical components

Rust and corrosion of metal parts, leading to reduced fit precision

SAP (Super Absorbent Polymer) gets damp and agglomerates, leading to uneven spreading and reduced product absorption performance

Non-woven fabrics and PE films get damp and stretch, leading to product size deviation

Hazards of excessively low humidity:

Generates a large amount of static electricity, leading to non-woven fabric deviation and dust adsorption, affecting product quality

Electrostatic discharge will damage precision electronic components such as PLC and servo drives

Operators are prone to static discomfort, affecting work efficiency

Solution: Install industrial dehumidifiers and humidifiers. Start the dehumidifier when the relative humidity is higher than 60%, and start the humidifier when the relative humidity is lower than 40%, keeping the workshop relative humidity stable at 40%-60% at all times.

3. Dust Control: Workshop Dust Concentration ≤10mg/m³

A large amount of fluff pulp and SAP dust will be generated during the underpad production process. If these dusts enter the equipment, they will cause serious damage to the equipment.

Hazards of dust:

Enters moving parts such as bearings and guide rails, leading to accelerated wear and shortened service life

Clogs sensors and proximity switches, leading to false triggers or missed detections

Adheres to the surface of electrical components, affecting heat dissipation and leading to overheating damage of components

Affects the accuracy of the vision inspection system, leading to misjudgment and missed inspection

Endangers the respiratory health of operators

Solution:

Install a central dust removal system, set up dust suction ports at each dust generation point of the equipment to collect and process dust centrally. The filtration accuracy of the dust removal system should reach below 5μm

Regularly clean the dust inside the equipment and on the workshop floor, and conduct a comprehensive dust cleaning at least once a week

Operators wear dust masks and protective glasses

The electrical control cabinets and servo drives of the equipment should adopt a sealed design to prevent dust from entering

4. Power Supply Stability: Voltage Fluctuation ≤±10%, Equipped with UPS Power Supply

A stable power supply is the basic guarantee for the normal operation of the equipment. Voltage fluctuations and sudden power outages will cause serious damage to the electrical system of the equipment.

Hazards of unstable power supply:

Voltage fluctuations exceeding ±10% will cause servo drive alarm shutdown and even burning

Sudden power outages will lead to loss of PLC programs and confusion of equipment parameters

Sudden power outages will lead to scrapping of semi-finished products and waste of raw materials

Frequent power outages and incoming calls will impact electrical components and shorten their service life

Solution:

Equip the equipment with an AC voltage stabilizer with matching power to ensure that the input voltage is stable within ±10%

Equip an uninterruptible power supply (UPS). The capacity of the UPS should be able to support the equipment to shut down safely for at least 15 minutes, allowing operators time to complete the shutdown operation and avoid equipment and product damage

The power supply of the equipment should be wired separately to avoid sharing a line with other high-power equipment to prevent voltage fluctuations

Regularly check the power lines and grounding devices to ensure that the grounding resistance is less than 4Ω

5. Ground Foundation: Flat and Solid, Load-bearing Capacity ≥5t/㎡

The installation ground of the equipment directly affects the operation stability and precision of the equipment. Uneven ground will cause equipment vibration and accelerate component wear.

Ground requirements:

The equipment should be installed on a flat and solid concrete ground with a ground thickness of not less than 200mm and a load-bearing capacity of not less than 5t/㎡

The ground flatness error does not exceed 2mm/m, and the inclination does not exceed 1/1000

The ground should be dry, non-slip, free of oil and water

Installation requirements:

The equipment must be leveled with a level during installation, with a level error not exceeding 0.1mm/m

Shock-absorbing pads should be installed on the equipment base to reduce vibration and noise during equipment operation

Sufficient operation and maintenance space should be reserved around the equipment, no less than 2m on the front, and no less than 1m on the sides and back

VI. Common Fault Prevention and Quick Troubleshooting

Even with perfect maintenance, the equipment may occasionally have some minor faults. The following are the prevention and quick troubleshooting methods for some common faults:

Important Reminder: If you encounter a fault that cannot be solved, please contact our technical support team immediately. We provide 7×24 hours remote technical support and can diagnose and solve problems for you in the first time. For problems that cannot be solved remotely, we will arrange engineers to come to the site as soon as possible.

VII. Establish a Long-Term Partnership with Us

As your underpad machine supplier, our responsibility is not only to sell equipment, but also to help you achieve long-term stable profits. We provide the following comprehensive after-sales services and support:

12-24 months whole machine warranty: Free replacement of non-human damaged parts during the warranty period

7×24 hours remote technical support: Provide immediate assistance through telephone, video and remote diagnosis systems

Global on-site service: Our engineers can arrive at any major market in the world within 3-7 days

Lifelong technical upgrade: Provide continuous software upgrade and technical transformation services for your equipment

Regular return visits: We will regularly visit customers to understand the equipment operation status and provide maintenance suggestions

Operator retraining: Provide free operation and maintenance training for your new employees

Equipment Upgrade Service: With the continuous advancement of technology, we can provide upgrade and transformation services for your old equipment, such as adding a machine vision inspection system, upgrading the servo drive system, transforming into a biodegradable material production line, etc., to keep your equipment always competitive in the market.